Nitride semiconductor element and nitride semiconductor package

ABSTRACT

A nitride semiconductor element capable of accommodating GaN electron transfer layers of a wide range of thickness, so as to allow greater freedom of device design, and a nitride semiconductor element package with excellent voltage tolerance performance and reliability. On a substrate, a buffer layer including an AlN layer, a first AlGaN layer and a second AlGaN layer is formed. On the buffer layer, an element action layer including a GaN electron transfer layer and an AlGaN electron supply layer is formed. Thus, an HEMT element is constituted.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation Application of co-pending U.S.application Ser. No. 15/870,818, filed on Jan. 12, 2018, and allowed onMay 4, 2018, which is a Continuation Application of U.S. applicationSer. No. 15/271,759, filed on Sep. 21, 2016, now U.S. Pat. No.9,905,419, issued on Feb. 27, 2018, which is a Continuation Applicationof U.S. application Ser. No. 15/018,204, filed on Feb. 8, 2016, now U.S.Pat. No. 9,472,623, issued on Oct. 18, 2016, which is a ContinuationApplication of U.S. application Ser. No. 13/297,141, filed on Nov. 15,2011, now U.S. Pat. No. 9,257,548, issued on Feb. 9, 2016. Thisapplication claims the benefit of priority of Japanese PatentApplication No. 2010-255912, filed on Nov. 16, 2010. The disclosures ofthese prior applications are incorporated by reference herein.

BACKGROUND OF THE INVENTION Description of the Related Art

The so-called group III nitride semiconductor refers to a semiconductorformed by using nitrogen as a group V element in a group III-Vsemiconductor. Representative examples are AlN, GaN, and InN, andgenerally, may be denoted as Al_(x)In_(y)Ga_(1-x-y)N (0≤x≤1, 0≤y≤1,0≤x+y≤1).

This type of group III nitride semiconductor has physical propertiessuitable for us application in high-temperature, high-power,high-frequency devices. In view of these physical properties, the groupIII nitride semiconductor is used as a semiconductor in devices such asa High Electron Mobility Transistor (HEMT).

For example, an HEMT having a Si substrate, an AlN layer, an AlGaN layer(with an Al component of greater than 0.3 and below 0.6), a GaN layerand an AlGaN electron supply layer is proposed. The AlN layer, the AlGaNlayer, the GaN layer and the AlGaN electron supply layer aresequentially laminated on the Si substrate through epitaxial growth(referring to a patent document of Japanese Patent Publication No.2008-166349).

SUMMARY OF THE INVENTION

However, in the HEMT of Patent Document 1, the difference in latticeconstant between the AlGaN layer and the GaN layer is large, so if a GaNlayer with a large thickness is laminated, lattice relaxation of GaN iscaused, the compression stress applied on the GaN layer disappears, anda tensile stress is generated due to the difference in linear expansioncoefficient between the Si substrate and GaN. Consequently, fine cracks(alligator cracks) are generated on the GaN layer. This imposespractical limits on GaN layer thickness, thus constraining devicedesign.

Therefore, the present invention is directed to a nitride semiconductorelement capable of accommodating GaN electron transfer layers of a widerange of thickness, so as to allow greater freedom of device design.

The present invention is further directed to a nitride semiconductorelement package with excellent voltage withstanding performance andreliability.

In order to achieve the objectives, a model of Technical Solution 1employs a nitride semiconductor element, which includes: a Si substrate;a buffer layer, including an AlN layer formed on a primary surface ofthe Si substrate and an AlGaN deposit layer formed by laminatingmultiple AlGaN layers on the AlN layer; a Group III-nitride electrontransfer layer, formed on the AlGaN deposit layer; and a GroupIII-nitride electron supply layer, formed on the Group III-nitrideelectron transfer layer. In the AlGaN deposit layer, the Al component ofa reference AlGaN layer is lower than the Al component of an AlGaN layerwith respect to the reference AlGaN layer being more close to a side ofthe AlN layer. In other words, multiple AlGaN layers preferably includea first AlGaN layer, and a second AlGaN layer, in which the second AlGaNlayer is configured at an opposite side of the AlN layer (the GaNelectron transfer layer side) relative to the first AlGaN layer, and theAl component of the second AlGaN layer is lower than that of the firstAlGaN layer.

According to their manner of constitution, the multiple AlGaN layers areformed such that the closer to the Group III-nitride electron transferlayer a layer is, the smaller the Al component becomes. Therefore, thelattice constant of the AlGaN layer can gradually increase from aninitial value close to the lattice constant of AlN to a value close tothe lattice constant of the Group III-nitride electron transfer layer.Therefore, the difference in lattice constant between the GroupIII-nitride electron transfer layer and the AlGaN layer connected to thetop layer of the Group III-nitride electron transfer layer can bereduced. In this way, freedom of design is permitted in selecting thethickness of the Group III-nitride electron transfer layer, such as athick Group III-nitride electron transfer layer to provide improvedperformance of the element in voltage tolerance.

However, in the case where the GaN crystalline is to be laminated on theSi substrate through epitaxial growth, sometimes during cooling or aftercooling after the epitaxial growth, a large tensile stress is generatedon the GaN layer due to the difference in thermal expansion coefficientbetween the Si substrate and the GaN layer (that is, the difference incontraction rate during cooling). Consequently, fine cracks (alligatorcracks) are generated on the GaN layer and the Si substrate becomeswarped.

According to the present invention, the AlN layer is formed on the Sisubstrate, and the AlGaN deposit layer is disposed between the AlN layerand the Group III-nitride electron transfer layer. Furthermore, in theAlGaN deposit layer, multiple AlGaN layers are formed in such a mannerthat the closer to the Group III-nitride electron transfer layer a layeris, the smaller the Al component becomes. Therefore, the compressionstress (strain) applied to the AlGaN layer due to the difference inlattice constant between the AlN layer and the AlGaN layer at the bottomlayer can be transferred to the AlGaN layer at the top layer. In thisway, even if a tensile stress is generated on the Group III-nitrideelectron transfer layer, the tensile stress may also be mitigatedthrough the compression stress applied to the Group III-nitride electrontransfer layer from the AlN layer and the AlGaN buffer layer. Therefore,the alligator cracks of the Group III-nitride electron transfer layerand the warp of the Si substrate can be alleviated.

Furthermore, in the AlGaN deposit layer, as shown in Technical Solution2, the difference in Al component (%) between the reference AlGaN layerand the AlGaN layer configured on a surface of the AlN layer connectedthe reference AlGaN layer preferably is 10% or more.

As a result, a difference in lattice constant between the referenceAlGaN layer and the AlGaN layer connected to the reference AlGaN layeris definitely generated.

For example, if the difference in Al component (%) between the referenceAlGaN layer and the AlGaN layer configured on the surface of the AlNlayer connected the reference AlGaN layer is about 1%, sometimes thelattice constant of the reference AlGaN layer will be consistent withthe lattice constant of the AlGaN layer connected to the reference AlGaNlayer. Therefore, the difference in lattice constant between the AlGaNlayer at the top layer and the Group III-nitride electron transfer layerincreases, resulting in complete lattice relaxation, so it is difficultto transfer the compression stress (strain) from the buffer layer to theGroup III-nitride electron transfer layer.

Therefore, in comparison with the case where a consistent latticeconstant is generated, the model of Technical Solution 2 provides areduced difference in lattice constant between the Group III-nitrideelectron transfer layer and the AlGaN layer. Therefore, the compressionstress (strain) may be effectively transferred from the buffer layer tothe Group III-nitride electron transfer layer, thereby alleviating theproblems of alligator cracks appearing in the Group III-nitride electrontransfer layer and warping of the Si substrate.

For example, as shown in Technical Solution 3, the AlGaN deposit layermay also include a construction formed of the first AlGaN layer with anAl component of 50% and the second AlGaN layer with an Al component of20% sequentially laminated from the start of the AlN layer.

Furthermore, as shown in Technical Solution 4, the AlGaN deposit layermay also include a construction formed of the first AlGaN layer with anAl component of 80%, the second AlGaN layer with an Al component of 60%,the third AlGaN layer with an Al component of 40% and the fourth AlGaNlayer with an Al component of 20% sequentially laminated from the startof the AlN layer.

Furthermore, the model of Technical Solution 5 is the nitridesemiconductor according to any one of Technical Solutions 1 to 4, inwhich the plane orientation of the primary surface of the buffer layeris the c-plane, and in the AlGaN deposit layer, the a-axis averagelattice constant of the reference AlGaN layer is greater than the a-axisin-plane lattice constant of the AlGaN layer configured on the surfaceof the AlN layer connected the reference AlGaN layer, and is lower thanthe original a-axis average lattice constant of the reference AlGaNlayer.

In this way, the a-axis average lattice constant of the reference AlGaNlayer is greater than the a-axis in-plane lattice constant of the AlGaNlayer connected to the reference AlGaN layer, and is lower than theoriginal a-axis average lattice constant of the reference AlGaN layer(the a-axis lattice constant under the state of no-strain). Thus, thea-axis compression stress due to inconsistency of the a-axis latticeconstant of the AlGaN layer configured on the surface of the AlN layerconnected the reference AlGaN layer is applied to the reference AlGaNlayer. Furthermore, the a-axis compression stress can be transferred tothe AlGaN layer at the top layer. Therefore, even if the a-axis tensilestress is generated on the Group III-nitride electron transfer layer,the a-axis tensile stress may also be mitigated by applying the a-axiscompression stress to the Group III-nitride electron transfer layer fromthe AlN layer and the AlGaN buffer layer.

The so-called in-plane lattice constant refers to the lattice constantof an interface between the AlGaN layer connected to the side of the AlNlayer of the reference AlGaN layer and the reference AlGaN layer.

Alternatively, the primary surface of the Si substrate can furthermorebe the (111) plane as shown in Technical Solution 6.

The degree of strain of the c-axis lattice constant of the GroupIII-nitride electron transfer layer preferably is −0.07% or more, asshown in Technical Solution 7.

Thus, alligator cracks can be prevented from forming on the GroupIII-nitride electron transfer layer.

The thickness of the Group III-nitride electron transfer layerpreferably is 500 nm to 2000 nm, as shown in Technical Solution 8.

The thickness of the AlN layer preferably is 50 nm to 200 nm, as shownin Technical Solution 9.

The thickness of the first AlGaN layer preferably is 100 nm to 500 nm,as shown in Technical Solution 10.

The thickness of the second AlGaN layer preferably is 100 nm to 500 nm,as shown in Technical Solution 11.

The model of Technical Solution 12 is a nitride semiconductor package,which includes the nitride semiconductor element according to any one ofTechnical Solutions 1 to 11 and a resin package formed in a manner ofcovering the nitride semiconductor element.

According to this way of using the nitride semiconductor element of thepresent invention, the degree of design freedom in the thickness of theGroup III-nitride electron transfer layer is high, so a package withexcellent voltage tolerance performance can be provided. Furthermore,the problems of alligator cracks forming on the Group III-nitrideelectron transfer layer and warping of the Si substrate of the nitridesemiconductor element can be alleviated, so a package with highreliability can be provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic global view of an HEMT package according to animplementation manner of the present invention;

FIG. 2 is a perspective view denoting the inside of the HEMT packageshown in FIG. 1;

FIG. 3 is an enlarged view of a part surrounded by dashed line A of FIG.2;

FIG. 4 is a schematic cross-sectional view of an HEMT element accordingto an implementation manner of the present invention, which denotes thecross section of the B-B cut surface of FIG. 3.

FIG. 5 is an image view of a residual stress generated on a nitridesemiconductor layer.

FIG. 6 is a graphical drawing for illustrating the constitution of aprocessing device used to grow layers constituting a group III nitridesemiconductor deposit layer.

FIG. 7 is a drawing illustrating a deformed example of the AlGaN depositlayer of FIG. 4.

FIG. 8 is a schematic cross-sectional view denoting the constitution ofan HEMT element according to an embodiment.

FIG. 9 is a chart denoting the degree of strain of the c-axis latticeconstant of the GaN electron transfer layer according to an embodiment.

FIG. 10 is a chart denoting the lattice constant of the second AlGaNlayer according to an embodiment.

PREFERRED EMBODIMENT OF THE PRESENT INVENTION

Implementation manners of the present invention are illustrated indetail below with reference to the accompanying drawings.

FIG. 1 is a schematic global view of an HEMT package according to animplementation manner of the present invention. FIG. 2 is a perspectiveview denoting the inside of the HEMT package shown in FIG. 1. FIG. 3 isan enlarged view of a part surrounded by dashed line A of FIG. 2.

As an example of a nitride semiconductor package according to thepresent invention, an HEMT package 1 includes a terminal frame 2, anHEMT element 3 (chip), and a resin package 4.

The terminal frame 2 is formed in the shape of a metal plate. Theterminal frame 2 has the shape of a quadrangle from the top view, andincludes a base portion 5 supporting the HEMT package 1; a sourceterminal 6 integrally formed with the base portion 5; and a drainterminal 7 and a gate terminal 8 formed separately from the base portion5.

The source terminal 6, the drain terminal 7 and the gate terminal 8 arerespectively formed in a top view straight line shape including one endand the other end, and the ends are parallel to each other in the sameorder. In the multiple terminals 6 to 8, only one end of the sourceterminal 6 integrally formed with the base portion 5 is connected to acorner portion of the base portion 5. In the other terminals 7 to 8, thegate terminal 8 is configured in a manner that one end thereof isopposite to another corner portion of the base portion 5 adjacent to thecorner portion connected to the source terminal 6, and the drainterminal 7 is configured between the gate terminal 8 and the sourceterminal 6.

The HEMT element 3 is an example of the nitride semiconductor elementaccording to the present invention, and includes a drain pad 9, a sourcepad 10 and a gate pad 11. The drain pad 9, the source pad 10 and thegate pad 11 are each formed in the shape of a metal plate, and areconfigured separately from each other.

The drain pad 9 integrally includes a welding portion 12D, a support armportion 13D and an electrode portion 14D.

The welding portion 12D of the drain pad 9 is formed in a top viewstraight line shape including one end and the other end, and extendingin a direction of transversely cutting the terminals 6 to 8 of theterminal frame 2. The welding portion 12D is electrically connected tothe drain terminal 7 through welding wires 15D (3 connection wires inFIG. 2).

The support arm portions 13D of the drain pad 9 are formed as a pair ina top view straight line shape extending in a direction far from theterminals 6 to 8 from the start of one end and the other end of thewelding portion 12D and are parallel to each other. The drain pad 9divides an element area 16 from which a movable end (the other end) ofthe support arm portion 13D is exposed and surrounded to form a top viewconcave shape (U-shaped) through the welding portion 12D and a pair ofsupport arm portions 13D.

The electrode portion 14D of the drain pad 9 is disposed in the elementarea 16, and is in a stripe shape extending from one support arm portion13D to the other support arm portion 13D, thus forming multipleelectrode portions 14D. Between a front end connected to an electrodeportion 14D on a support arm portion 13D and a front end connected to anelectrode portion 14D on the other support arm portion 13D, a gap 17with a specific width is disposed.

The source pad 10 integrally includes a welding portion 18S, a supportarm portion 19S and an electrode portion 20S.

The welding portion 18S of the source pad 10 forms a top view straightline shape extending in parallel to the welding portion 12D of the drainpad 9 at the exposure end of the element area 16. The welding portion18S is electrically connected to the base portion 5 through weldingwires 21S (2 connection wires in FIG. 2). In this way, the weldingportion 18S of the source pad 10 is electrically connected to the sourceterminal 6 integrally formed with the base portion 5.

The support arm portion 19S of the source pad 10 is formed as one piecein a manner extending in the direction transversely cutting theelectrode portion 14D of the drain pad 9 in the gap 17 of the electrodeportion 14D of the drain pad 9.

The electrode portion 20S of the source pad 10 is formed as multiplepieces in a stripe shape extending in two directions from the supportarm portion 19S to the support arm portions 13D of the drain pad 9. Anelectrode portion 20S is disposed between the electrode portions 14D ofthe drain pad 9.

The gate pad 11 integrally includes a welding portion 22G, a firstsupport arm portion 23G, a second support arm portion 24G and anelectrode portion 25G

The welding portion 22G of the gate pad 11 forms a top view quadrangleshape, and is configured close to a movable end of one support armportion 13D of the drain pad 9. The welding portion 22G is electricallyconnected to the gate terminal 8 through a welding wire 26G (1connection wire in FIG. 2).

The first support arm portion 23G of the gate pad 11 forms a top viewstraight line shape, from a corner portion of the welding portion 22G toa movable end of the other support arm portion 13D of the drain pad 9,and is close to a side of the element area 16 relative to the weldingportion 18S of the source pad 10 and extends in parallel to the weldingportion 12D of the drain pad 9.

The second support arm portion 24G of the gate pad 11 is formed as onepiece at two sides of the support arm portion 19S of the source pad 10respectively in a manner extending in a direction transversely cuttingthe electrode portion 14D of the drain pad 9 from the start of the firstsupport arm portion 23G, in the gap 17 of the electrode portion 14D ofthe drain pad 9.

The electrode portion 25G of the gate pad 11 is formed as multiplepieces in a stripe shape extending in two directions from the secondsupport aim portion 24G to the support arm portions 13D of the drain pad9. An electrode portion 25G is disposed between the electrode portion14D of the drain pad 9 and each electrode portion 20S of the source pad10. Furthermore, the interval GD between the electrode portion 25G andthe electrode portion 14D is wider than the interval GS between theelectrode portion 25G and the electrode portion 20S. That is, theelectrode portion 25G is configured at a side close to the electrodeportion 20S relative to the middle position between the electrodeportion 14D and the electrode portion 20S. Thus, when a positive voltageis applied to the electrode portion 14D at the drain side, and a voltagebelow 0 (zero) V is applied to the electrode portion 25G at the gateside, full voltage drop can be achieved between the drain and the gate.In this way, electrostatic focusing for the electrode portion 25G can beprevented.

The resin package 4 constitutes the profile of the HEMT package 1, andis formed into a basically cuboid shape. The resin package 4 includeswell-known mould resin such as epoxide resin, and covers the baseportion 5 of the terminal frame 2, the welding wires 15D, 21S, and 26G,and the HEMT element 3 together with 3 terminals (the source terminal 6,the drain terminal 7 and the gate terminal 8) exposed, thereby sealingthe HEMT element 3.

FIG. 4 is a schematic cross-sectional view of an HEMT element accordingto an implementation manner of the present invention, which denotes across section of a B-B cut surface of FIG. 3.

The internal construction of the HEMT element is described in detailbelow with reference to FIG. 4.

The HEMT element 3 includes a substrate 41 as a semiconductor substrate,and a group III nitride semiconductor deposit layer 42 formed on thesubstrate 41 through epitaxial growth (crystalline growth).

The substrate 41 in this implementation manner is constituted by a Simonocrystalline substrate (with a linear expansion coefficient al of,for example, 2.5×10⁻⁶ to 3.5×10⁻⁶ (293 K)). The substrate 41 is acoaxial (111) plane Si substrate with a (111) plane as a primary surface43 and a deflection angle of 0°.

The a-axis average lattice constant LC1 (the inter-lattice distancebetween Si atoms bonded to atoms constituting a nitride semiconductor inthe direction of the primary surface 43 of the substrate 41) of thesubstrate 41 is, for example, 0.768 nm to 0.769 nm. Furthermore, throughthe crystalline growth on the primary surface 43, the group III nitridesemiconductor deposit layer 42 is formed. The group III nitridesemiconductor deposit layer 42 includes, for example, a group IIInitride semiconductor with the c-plane ((0001) plane)) as the primarysurface for the crystalline growth.

Misalignment between layers forming the group III nitride semiconductordeposit layer 42 and the lattice at the bottom layer is absorbed throughthe lattice strain of the crystalline growth layer, thereby ensuringlattice continuity on the interface between the layers and the bottomlayer. For example, when the InGaN layer and the AlGaN layer arerespectively grown from the c-plane ((0001) plane)) of the GaN layer,the average lattice constant of InGaN in the a-axis direction under thestate of no strain (the a-axis average lattice constant) is greater thanthe a-axis average lattice constant of GaN, so the compression stress(compression strain) is generated on the InGaN layer in the directionfacing the a-axis. Accordingly, the a-axis average lattice constant ofAlGaN under the state of no strain is lower than the a-axis averagelattice constant of GaN, so the tensile stress (tensile strain) isgenerated on the AlGaN layer in the direction facing the a-axis.

The constitution of the group III nitride semiconductor deposit layer 42is a buffer layer 44, a GaN electron transfer layer 45, and an AlGaNelectron supply layer 46 sequentially laminated from the start of thesubstrate 41.

The buffer layer 44 is constituted by laminating an AlN layer 47, afirst AlGaN layer 48, and a second AlGaN layer 49. In the implementationmanner, the deposit layer of the first AlGaN layer 48 and the secondAlGaN layer 49 is an example of the AlGaN deposit layer of the presentinvention. Furthermore, the second AlGaN layer 49 is an example of thereference AlGaN layer of the present invention, and the first AlGaNlayer 48 is an example of the AlGaN layer configured on the surface ofthe AlN layer connected the reference AlGaN layer.

The thickness of the AlN layer 47 is 50 nm to 200 nm, for example, 120nm. Furthermore, the a-axis average lattice constant LC2 of the AlNlayer 47 is, for example, 0.311 nm to 0.312 nm, and the linear expansioncoefficient α2 is, for example, 4.1×10⁻⁶ to 4.2×10⁻⁶ (293 K).

The first AlGaN layer 48 in this implementation manner is formed into anundoped AlGaN layer without intentionally added impurities. However, thefirst AlGaN layer 48 sometimes contains minor unintentional impurities.

The thickness of the first AlGaN layer 48 is 100 nm to 500 nm, forexample, 140 nm. The average Al component of the first AlGaN layer 48 is40% to 60% (for example, 50%). The a-axis average lattice constant LC3of the first AlGaN layer 48 is, for example, 0.314 nm to 0.316 nm, andthe linear expansion coefficient α3 thereof is, for example, 4.6×10⁻⁶ to5.0×10⁻⁶ (293 K).

The a-axis in-plane lattice constant LC3′ of the upper surface of thefirst AlGaN layer 48 (the interface between the first AlGaN layer 48 andthe second AlGaN layer 49) is, for example, 0.312 nm to 0.314 nm.

The second AlGaN layer 49 in this implementation manner is formed intoan undoped AlGaN layer without impurities intentionally addedimpurities. However, the second AlGaN layer 49 sometimes contains minorunintentional impurities. The thickness of the second AlGaN layer 49 is100 nm to 500 nm, for example, 140 nm. Furthermore, the average Alcomponent of the second AlGaN layer 49 is lower than that of the firstAlGaN layer 48 by 10% or more, specifically, by 10% to 30% (for example20%). Furthermore, the a-axis average lattice constant LC4 of the secondAlGaN layer 49 is greater than the a-axis in-plane lattice constant LC3′of the upper surface of the first AlGaN layer 48 (the interface betweenthe first AlGaN layer 48 and the second AlGaN layer 49), and lower thanthe original a-axis average lattice constant (0.316 nm to 0.318 nm) ofAlGaN, for example, 0.314 nm to 0.316 nm. Furthermore, the linearexpansion coefficient α4 of the second AlGaN layer 49 is, for example,5.0×10⁻⁶ to 5.4×10⁻⁶ (293 K).

The GaN electron transfer layer 45 in this implementation manner isformed into an undoped GaN layer without intentionally added impurities.However, the GaN electron transfer layer 45 sometimes contains minorunintentional impurities. The a-axis average lattice constant LC5 of theGaN electron transfer layer 45 is, for example, 0.318 nm to 0.319 nm,and the linear expansion coefficient α5 is, for example, 5.5×10⁻⁶ to5.6×10⁻⁶ (293 K).

Furthermore, the degree of strain of the c-axis lattice constant of theGaN electron transfer layer 45 is, for example, −0.07% or more and below0 (zero). The degree of strain of the c-axis lattice constant isobtained, for example, by comparing the c-axis lattice constant of theGaN electron transfer layer 45 determined through X-ray diffractiondetermination, with the original c-axis lattice constant of GaN. As longas the degree of strain of the c-axis lattice constant of the GaNelectron transfer layer 45 is in the range, the applied c-axiscompression stress can be constrained, so as to prevent generation ofalligator cracks.

An orthogonal relationship exists between the c-axis and the a-axis.Therefore, as shown in FIG. 5, the compression stress and the tensilestress apply force in opposite directions; that is, whatever directionthe compression stress is applied to (for example the c-axis direction),the tensile stress is applied to the opposite direction (for example thea-axis direction).

Therefore, as described above, the degree of strain of the c-axislattice constant of the GaN electron transfer layer 45 is set to begreater than 0.07% and below 0 (zero), and the c-axis compression stressapplied to the GaN electron transfer layer 45 may be constrained, so asto prevent generation of alligator cracks.

The AlGaN electron supply layer 46 in this implementation manner isformed into an undoped AlGaN layer without intentionally addedimpurities. However, the AlGaN electron supply layer 46 sometimescontains minor unintentional impurities. The a-axis average latticeconstant LC6 of the AlGaN electron supply layer 46 is, for example,0.318 nm to 0.319 nm. Furthermore, the average Al component of the AlGaNelectron supply layer 46 is 20% to 30% (for example 25%). Furthermore,the linear expansion coefficient α6 of the AlGaN electron supply layer46 is, for example, 5.0×10⁻⁶ to 5.2×10⁻⁶ (293 K).

In this way, bonding between the GaN electron transfer layer 45 and theAlGaN electron supply layer 46 with components different from each otherbecomes heterogeneous bonding, and so, on the GaN electron transferlayer 45, two-dimensional (2D) electron gas (2DEG) is generated close tothe bonding interface between the GaN electron transfer layer 45 and theAlGaN electron supply layer 46. The 2DEG spreads basically over theentire area close to the bonding interface between the GaN electrontransfer layer 45 and the AlGaN electron supply layer 46, and theconcentration thereof is, for example, 8×10¹² cm⁻² to 2×10¹³ cm⁻². Inthe HEMT element 3, a current flow is formed between the source and thedrain by utilizing the 2DEG so as to execute an element action.

On the AlGaN electron supply layer 46, in a manner of being connected tothe AlGaN electron supply layer 46, the electrode portion 25G of thegate pad 11, the electrode portion 20S of the source pad 10 and theelectrode portion 14D of the drain pad 9 are separately disposed atintervals.

The electrode portion 25G of the gate pad 11 (referred to as a gateelectrode 25G hereinafter) may be constituted by an electrode materialcapable of forming Schottky bonding with the AlGaN electron supply layer46, for example, Ni/Au (Ni/Au alloy).

The electrode portion 20S of the source pad 10 (referred to as a sourceelectrode 20S hereinafter) and the electrode portion 14D of the drainpad 9 (referred to as a drain electrode 14D hereinafter) both may beconstituted by an electrode material capable of achieving ohmicconnection with the AlGaN electron supply layer 46, for example, Ti/Al(Ti/Al alloy), Ti/Al/Ni/Au (Ti/Al/Ni/Au alloy), Ti/Al/Nb/Au (Ti/Al/Nb/Aualloy), and Ti/Al/Mo/Au (Ti/Al/Mo/Au alloy).

Furthermore, a back electrode 51 is formed at the back side of thesubstrate 41. The back electrode 51 is connected to the base portion 5of the terminal frame 2, so that the potential of the substrate 41becomes the ground potential. Additionally, the potential of thesubstrate 41 may also be set to be the same as that of the sourceelectrode 20S, so that the potential of the source electrode 20S becomesthe ground potential.

FIG. 6 is a graphical drawing illustrating the constitution of aprocessing device used for growing layers constituting a group IIInitride semiconductor deposit layer.

A method for manufacturing a group III nitride semiconductor depositlayer is described in detail below with reference to FIG. 6.

A base 62 equipped with a heater 61 is configured in a processingchamber 60. The base 62 is bound to a rotation axis 63, and the rotationaxis 63 is rotated by utilizing a rotation drive mechanism 64 configuredoutside the processing chamber 60. Thus, a processing object, that is, achip 65, is maintained on the base 62; the chip 65 may be heated to aspecific temperature in the processing chamber 60, and may be rotated.The chip 65 is a Si monocrystalline chip constituting the Simonocrystalline substrate 41.

An exhaustion pipe 66 is connected to the processing chamber 60. Theexhaustion pipe 66 is an exhaustion apparatus connected to a rotationpump. Thus, the pressure in the processing chamber 60 is set to 1/10barometric pressure to atmospheric pressure, so as to continuouslyperform exhaustion on the processing environment in the processingchamber 60.

In another aspect, a raw material gas supply pipe 70 for supplying rawmaterial gas to the surface of the chip 65 maintained on the base 62 isintroduced into the processing chamber 60. The raw material gas supplypipe 70 is connected to a nitrogen raw material pipe 71 for supplyingammonia as nitrogen raw material gas, a gallium raw material pipe 72 forsupplying trimethylgallium (TMG) as gallium raw material gas, an Al rawmaterial pipe 73 for supplying trimethylaluminum (TMAl) as Al rawmaterial gas, a boron raw material pipe 74 for supplying Triethyl boron(TEB) as boron raw material gas, a magnesium raw material pipe 75 forsupplying ethylcyclopentadienyl magnesium (EtCp₂Mg) as magnesium rawmaterial gas, a silicon raw material pipe 76 for supplying silane (SiH₄)as silicon raw material gas, and a carrier air pipe 77 for supplying thecarrier gas. Valves 81 to 87 are mounted in the multiple raw materialpipes 71 to 77 respectively. All raw material gases are suppliedtogether with the carrier gas including hydrogen or nitrogen or both.

For example, the Si monocrystalline chip, with the (111) plane as theprimary surface, is used as the chip 65 and maintained on the base 62.In this state, the valves 81 to 86 are closed, and the carrier air valve87 is opened, so as to supply the carrier gas to the processing chamber60. Moreover, the heater 61 is powered on to heat the chip to atemperature of 1000° C. to 1100° C. (for example 1050° C.). Thus, agroup III nitride semiconductor with the surface coarsely growing cannotbe generated.

When the chip temperature reaches 1000° C. to 1100° C. and the heater ison standby, the nitrogen raw material valve 81 and the Al raw materialvalve 83 are opened. Thus, ammonia and TMAl are supplied together withthe carrier gas from the raw material air supply pipe 70. In this way,the AlN layer 47 is formed on the surface of the chip 65 throughepitaxial growth.

Then, the first AlGaN layer 48 is formed. That is to say, the nitrogenraw material valve 81, the gallium raw material valve 82 and the Al rawmaterial valve 83 are opened, and the other valves 84 to 86 are closed.Thus, ammonia, TMG and TMAl are supplied to the chip 65, so as to formthe first AlGaN layer 48 containing AlGaN. When the first AlGaN layer 48is formed, the temperature of the chip 65 is properly set to between1000° C. and 1100° C. (for example 1050° C.).

Then, the second AlGaN layer 49 is formed. That is to say, the nitrogenraw material valve 81, the gallium raw material valve 82 and the Al rawmaterial valve 83 are opened, and the other valves 84 to 86 are closed.Thus, ammonia, TMG and TMAl are supplied to the chip 65, so as to formthe second AlGaN layer 49 containing AlGaN. When the second AlGaN layer49 is formed, the temperature of the chip 65 is properly set to between1000° C. and 1100° C. (for example 1050° C.).

Afterwards, the GaN electron transfer layer 45 is formed. When the GaNelectron transfer layer 45 is formed, the nitrogen raw material valve 81and the gallium raw material valve 82 are opened, and ammonia and TMGare supplied to the chip 65, thereby growing the GaN layer. When the GaNelectron transfer layer 45 is formed, the temperature of the chip 65 isproperly set to, for example, between 1000° C. and 1100° C. (for example1050° C.).

Then, the AlGaN electron supply layer 46 is formed. That is to say, thenitrogen raw material valve 81, the gallium raw material valve 82 andthe Al raw material valve 83 are opened, and the other valves 84 and 85are closed. Thus, ammonia, TMG and TMAl are supplied to the chip 65, soas to form the AlGaN electron supply layer 46. When the AlGaN electronsupply layer 46 is formed, the temperature of the chip 65 is properlyset to between 1000° C. to 1100° C. (for example 1050° C.).

Subsequently, the chip 65 is placed at room temperature for 20 min to 60min for cooling. In this way, the group III nitride semiconductordeposit layer 42 is formed.

As described above, according to this implementation manner, the bufferlayer 44 formed by sequentially laminating the AlN layer 47, the firstAlGaN layer 48 (with an average Al component of 50%) and the secondAlGaN layer 49 (with an average Al component of 20%) is disposed on theSi monocrystalline substrate 41, and the GaN electron transfer layer 45is connected to the primary surface (c-plane) of the second AlGaN layer49.

Thus, the a-axis average lattice constant from the AlN layer 47 to theGaN electron transfer layer 45 is continuously increased from LC2 (0.311nm), LC3 (0.314 nm) and LC4 (0.316 nm) to the value close to the a-axisaverage lattice constant LC5 (0.318 nm) of the GaN electron transferlayer in a periodic manner. Therefore, the difference in a-axis averagelattice constant (LC5-LC4) between the GaN electron transfer layer 45and the second AlGaN layer 49 connected to the GaN electron transferlayer 45 may be reduced. In this way, the GaN electron transfer layer 45can be freely designed in terms of thickness. Therefore, the GaNelectron transfer layer 45 can be designed to be thick, so as to improvethe voltage tolerance performance of the HEMT element 3.

Furthermore, the compression stress applied to the first AlGaN layer 48due to the difference in a-axis average lattice constant (LC3-LC2)between the AlN layer 47 and the first AlGaN layer 48 may be transferredto the second AlGaN layer 49. Thus, the a-axis average lattice constantLC4 of the second AlGaN layer 49 is greater than the a-axis in-planelattice constant LC3′ of the first AlGaN layer 48 connected to thesecond AlGaN layer 49, and is lower than the original a-axis averagelattice constant of the second AlGaN layer 49. That is, the a-axiscompression stress due to inconsistency of the a-axis in-plane latticeconstant LC3′ of the first AlGaN layer 48 is applied to the second AlGaNlayer 49. Furthermore, the a-axis compression stress may be applied tothe GaN electron transfer layer 45.

Therefore, during or after cooling after the group III nitridesemiconductor deposit layer 42 is formed, even if the tensile stress isgenerated on the GaN electron transfer layer 45 due to the difference inlinear expansion coefficient (α5-α1) between the substrate 41 and theGaN electron transfer layer 45, the tensile stress may also be mitigatedby applying the compression stress to the GaN electron transfer layer 45from the second AlGaN layer 49.

In this way, as described above, the degree of strain of the c-axislattice constant of the GaN electron transfer layer 45 may be set to behigher than −0.07% and below 0 (zero); that is to say, the GaN electrontransfer layer 45 can be maintained in a state wherein the a-axistensile stress is applied such that alligator cracks are not generated.Therefore, the problems of alligator cracks appearing in the GaNelectron transfer layer 45 and warping of the substrate 41 can bealleviated.

The above embodiment serves to illustrate one implementation manner ofthe present invention, but the present invention may also be implementedthrough other manners.

For example, the AlGaN deposit layer of the buffer layer 44 is notnecessarily constituted by two AlGaN layers 48 and 49 having differentAl components; it may for example also be constituted by the first AlGaNlayer 52 (with an average Al component of, for example 80%), the secondAlGaN layer 53 (with an average Al component of, for example, 60%), thethird AlGaN layer 54 (with an average Al component of, for example, 40%)and the fourth AlGaN layer 55 (with an average Al component of, forexample, 20%) sequentially laminated from the start of the AlN layer 47as shown in FIG. 7. Alternatively, the AlGaN deposit layer may beconstituted by laminating three AlGaN layers, five AlGaN layers, or morethan five AlGaN layers with different Al components.

Furthermore, various design modifications may be implemented within thescope recorded in the Claims.

The present invention is described below based on an embodiment forpurpose of illustration without limitation.

The aim of the embodiment is to confirm the changes in degree of strainof the c-axis lattice constant of the GaN electron transfer layer andthe lattice constant of the second AlGaN layer induced by the change ofthe Al component of the second AlGaN layer.

First, on a surface of a Si monocrystalline substrate with the (111)plane as the primary surface, the AlN layer (with a thickness of 120 nm)is formed through epitaxial growth. Then, the first AlGaN layer (averageAl component being 50% and the thickness being 140 nm) and the secondAlGaN layer (average Al component being 10% and the thickness being 140nm) are sequentially generated through epitaxial growth. Thus, thebuffer layer is formed.

Afterwards, the GaN electron transfer layer (with a thickness of 1000nm) and the AlGaN electron supply layer are sequentially formed on thesecond AlGaN layer, thereby manufacturing the group III nitridesemiconductor deposit layer as shown in FIG. 8. Subsequently, a sourceelectrode and a drain electrode are formed on the AlGaN electron supplylayer.

Likewise, a group III nitride semiconductor deposit layer with thesecond AlGaN layer with an Al component of 17% and 25% in place of thesecond AlGaN layer with an average Al component of 10% is manufactured.

<Evaluation>

(1) Determination of the C-Axis Degree of Strain of the GaN ElectronTransfer Layer

X-ray diffraction determination is performed on the GaN electrontransfer layer of the group III nitride semiconductor deposit layerobtained in the embodiment, so as to determine the c-axis latticeconstant of the GaN electron transfer layer. Thus, the direction and themagnitude of the residual stress applied to the GaN electron transferlayer are evaluated. The result is shown in FIG. 9.

It can be ascertained from FIG. 9 that no matter what the average Alcomponent of the second AlGaN layer is, the residual stress of the GaNelectron transfer layer is compressed relative to the c-axis (stretchedrelative to the a-axis). It is considered that this case is caused dueto the difference in linear expansion coefficient between the Simonocrystalline substrate and the GaN electron transfer layer.

That is, although the a-axis tensile stress is applied to the GaNelectron transfer layer, the c-axis degree of strain is higher than−0.07; in other words, it is determined that the a-axis tensile stressis of a proper magnitude without causing generation of alligator crackson the GaN electron transfer layer.

Furthermore, it can be ascertained that when average Al component of thesecond AlGaN layer is 17%, the residual stress of the GaN electrontransfer layer is lowest; this is the optimal value of the threeembodiments.

(2) Determination of the Lattice Constant of the Second AlGaN Layer

X-ray diffraction determination is performed on the second AlGaN layerof the group III nitride semiconductor deposit layer obtained in theembodiment, so as to determine the a-axis lattice constant of the secondAlGaN layer. The result is shown in FIG. 10. Table 1 shows thedifference in a-axis lattice constant between the second AlGaN layer andthe GaN electron transfer layer.

TABLE 1 Difference in a-axis lattice constant between the second AlGaNlayer and the Average Al component (%) GaN electron transfer layer (%)10 0.34 17 0.62 25 0.91

In FIG. 10, the straight line denotes a relationship between theoriginal c-axis lattice constant and the original a-axis latticeconstant of the AlGaN layer. The ink dot at the left side of thestraight line signifies that the AlGaN layer denoted by the ink dot issubject to the a-axis compression stress, and the ink dot at the rightside signifies that the AlGaN layer denoted by the ink dot is subject tothe a-axis tensile stress. Furthermore, the distance between thestraight line and the ink dot denotes the magnitude of the stress. Thatis, the larger the distance between the straight line and the ink dot,the greater the stress applied to the AlGaN layer denoted by the inkdot.

It can be known from FIG. 10 that no matter what the average Alcomponent of the second AlGaN layer is, a proper a-axis compressionstress is applied to the second AlGaN layer. Thus, it is determined thatthe a-axis compression stress acts on the GaN electron transfer layer,so as to mitigate the tensile stress caused due to the difference inlinear expansion coefficient between the Si monocrystalline substrateand the GaN electron transfer layer.

Although the technical contents and features of the present disclosureare described above, various replacements and modifications can be madeby persons skilled in the art based on the teachings and disclosure ofthe present description without departing from the spirit thereof.Therefore, the scope of the present disclosure is not limited to thedescribed embodiments, but covers various replacements and modificationsthat do not depart from the present disclosure as defined by theappended claims.

What is claimed is:
 1. A nitride semiconductor element, comprising: a Sisubstrate including a primary surface; a buffer layer comprised of anAlGaN laminated structure; a Group III-nitride electron transfer layerformed on the AlGaN laminated structure; and a Group III-nitrideelectron supply layer formed on the Group III-nitride electron transferlayer, wherein the AlGaN laminated structure has an average latticeconstant in the horizontal direction, the average lattice constant ofthe AlGaN laminated structure being lower than an original averagelattice constant of an original AlGaN layer.
 2. The nitridesemiconductor element of claim 1, wherein the AlGaN laminated structureis applied by a compression stress in the horizontal direction.
 3. Thenitride semiconductor element of claim 1, wherein the AlGaN laminatedstructure comprises: a first AlGaN layer; and a second AlGaN layer hasan Al component that is lower than an Al component of the first AlGaNlayer, wherein the first AlGaN layer is closer to an AlN layer formed onthe primary surface of the Si substrate than the second AlGaN layer. 4.The nitride semiconductor element according to claim 3, wherein thefirst AlGaN layer and the second AlGaN layer are compressed in thehorizontal direction.
 5. The nitride semiconductor element according toclaim 3, wherein the difference in the Al component between the originalAlGaN layer and the first AlGaN layer arranged in contact with thesurface of the original AlGaN layer is 10% or more.
 6. The nitridesemiconductor element according to claim 3, wherein the Al component ofthe first AlGaN layer is 50% and the Al component of the original AlGaNlayer is 10%.
 7. The nitride semiconductor element according to claim 3,wherein the Al component of the first AlGaN layer is 50% and the Alcomponent of the original AlGaN layer is 17%.
 8. The nitridesemiconductor element according to claim 3, wherein the Al component ofthe first AlGaN layer is 50% and the Al component of the original AlGaNlayer is 20%.
 9. The nitride semiconductor element according to claim 3,wherein the Al component of the first AlGaN layer is 50% and the Alcomponent of the original AlGaN layer is 25%.
 10. The nitridesemiconductor element according to claim 3, wherein the AlN layer has afirst horizontal average lattice constant, the Group III-nitrideelectron transfer layer has a second horizontal average latticeconstant, and the original average lattice constant of the originalAlGaN layer and the horizontal in-plane lattice constant of the firstAlGaN layer are greater than the first horizontal average latticeconstant and smaller than the second horizontal average latticeconstant.
 11. The nitride semiconductor element according to claim 10,wherein the first horizontal average lattice constant, the horizontalin-plane lattice constant of the first AlGaN layer, the original averagelattice constant of the original AlGaN layer, and the second horizontalaverage lattice constant are monotonic increasing values.
 12. Thenitride semiconductor element according to claim 1, wherein the originalAlGaN layer is arranged to compress the Group III nitride electrontransfer layer in the horizontal direction.
 13. The nitridesemiconductor element according to claim 1, wherein the first AlGaNlayer is arranged to compress the original AlGaN layer in the horizontaldirection.
 14. The nitride semiconductor element according to claim 3,wherein the AlN layer is stretched by the first AlGaN layer in thehorizontal direction.
 15. The nitride semiconductor element according toclaim 1, wherein the primary surface of the Si substrate is a (111)plane.
 16. The nitride semiconductor element according to claim 1,wherein the Group III-nitride electron transfer layer has a thickness of500 nm to 2000 nm.
 17. The nitride semiconductor element according toclaim 1, wherein the Group III-nitride electron supply layer has athickness of 500 nm to 2000 nm.
 18. The nitride semiconductor elementaccording to claim 3, wherein the AlN layer has a thickness of 50 nm to200 nm.
 19. The nitride semiconductor element according to claim 1,wherein the first AlGaN layer has a thickness of 100 nm to 500 nm. 20.The nitride semiconductor element according to claim 1, wherein theoriginal AlGaN layer has a thickness of 100 nm to 500 nm.